Continuous strand package supply and method of forming and of unwinding the same



Dec. 8, 1964 J. BARNETT, JR 3,160,365

CONTINUOUS STRAND PACKAGE SUPPLY AND METHOD OF FORMING AND 0F UNWINDING THE SAME Filed Aug. 3, 1962 dh Fl 77, 56 5| INVENTOR. J'ouPl-l Dunn-Ja- ATTORNEY United States Patent Ofifice 3,160,365 Patented Dec. 8, 1964 3,160,365 CONTINUOUS STRAND PACKAGE SUPPLY AND METHOD OF FORMING AND OF UNWINDING THE SAME Joseph Barnett, Jr., Toledo, Ohio, assignor to Johns-Manville Corporation, New York, N.Y., a corporation of New York Filed Aug. 3, 1962, Ser. No. 214,709 10 Claims. (Cl. 242-128) This invention generally relates to yarn packaging. More particularly, it relates to the provision of yarn material in continuous fashion for furnishing the same to processing equipment. Still more particularly, this invention relates to a packed carton of yarn roving packages and method of packaging the carton for continuous delivery.

In the textile trade, continuous yarns are formed into cylindrical packages to facilitate transportation to various other equipment for further processing. Since most of the further processing is conducted on a continuous basis, it would be advantageous to have a carton of yarn packages arranged so that such further processing may be conducted without interruption upon exhaustion of a single package.

Presently, in the supplying of yarn to a continuous operation, such as twisting, cutting, chopping or the like, a magazine creel is utilized to hold the individual packages. When the individual packages are nearly exhausted, an attendant ties a tail end of a first package to the forward end of a second package so that the operation may be conducted in a continuous fashion. It becomes apparent that a great deal of time and attention is required on the part of the attendant, particularly when the operation involves a plurality of running strands being simultaneously processed.

It is accordingly an object of this invention to provide a supply of yarn packages arranged in a manner whereby a plurality of packages may be unwound and the running strand transferred from one package to another Without interrupting the process.

Another object of this invention is to provide a carton of yarn packages comprising a plurality of superposed layers arranged so that a running strand is transferred from a first layer of packages to another layer of packages without interruption.

An embodiment of this invention to be described in detail involves a plurality of superposed layers of roving packages forming columns or tiers within a packing carton, each of the layers being separated by platforms. The packages are arranged in rows and adjacent packages, within a row, are secured together so that each of the packages within a row are interconnected to form a single continuous strand. Preferably, each of the packages is provided with a forward access end and a tail access end, and the forward access end of a subsequent package is secured to the tail access end of a preceding package. An end package of each superposed row is also secured to an end package of a subjacent row. Thus a continuous series comprising all of the packages in a c l n of rows is provided from which a continuous strand may be withdrawn. Roving packages are usually made to be unwound from the interior of the package. Consequently, to facilitate transfer from a superposed row to a subjacent row, an opening is provided in the plat form beneath the end package from whence the transfer takes place. According to this invention, there are also provided inserts which together with the platforms define compartments which prevent the packages from touching and abrading each other. The invention further contemplates an outer carton cover having means, preferably in the form of tear tapes, to facilitate exposure of a layer of packages at a time.

Further objects and advantages of this invention will appear from the following description of specific embodirnents thereof and from the accompanying drawings in which:

FIG. 1 is a pictorial view of a packed carton of this invention, with a portion broken away to disclose the interior of the carton.

FIG. 2 is an exploded pictorial view of the internal components of the carton of this invention, and

FIG. 3 is a cross-sectional elevational view of a packed carton embodying the invention and shown in conjunction with a continuous process machine.

Referring to the drawings, in FIG. 1 the carton generally designated by the numeral 10, which may be formed from cardboard, corrugated board, or other suitable material, comprises an outer protective cover 12 including a removable top 14, sides16, 18, 20 and 22 and bottom 24. The sides 16, 18, 20 and 22 are preferably prescored, as by die cutting, as indicated by broken lines 26 to provide tear strips 28. The tear strips 28 provide means whereby the interior of the carton =10 may be exposed a layer at a time and thereby facilitate removal of the roving packages 32. A starting tab 30 is also provided for each strip 28 for tearing the strip. It will be understood that the carton 10 may also comprise a plurality of superposed sections joined together by means such as adhesive strips to facilitate removal of the roving packages, a layer at a time.

In FIG. 3, the carton 10 is shown to contain a plurality of roving packages 32 arranged in layers 34, 36 and 38. Each of the superposed layers 34 and 36 is supported upon a platform 42 while layer 38 is supported by bottom 24. The packages 32 are arranged the layer in rows extending along phantom lines 44. Each row within a layer together with the corresponding rows of the subjacent packages form a series from which series a continuous strand may be unwound. The arrows of lines 44 indicate the direction the roving strand will advance as it is being unwound and the order in which the individual packages will be exhausted. The forward ends 31 of the subsequent packages are indicated as being secured to the tails 33 of the preceding packages. The method of forming the tail-ties may correspond to that disclosed in U.S. Patent No 2,898,054. Intermediate the individual packages 32 of a layer are disposed inserts 48 and 50 which mate to form a crisscross patterned grid 49 and which defines a plurality of compartments with the platforms 42 for retaining the individual packages 32 and thus prevent the packages fiom shifting into engagement with each other during transit and possible abrasion. The grid 49 is positioned over and deters shifting of the strand portions 31 and 32 interconnecting strand packages 32. The transfer of the strand, a column, from a package of one layer to a package of another layer, is facilitated by providing the platform 42 with an opening 46 at the end of the row where the transfer occurs. However, in order to obviate the necessity of the packer to predetermine which direction and end the strand transfer from one layer to another is to take place, both end compartments of a row are provided with an opening 46.

It will be apparent that a method and means have been provided by this invention whereby the individual packages of a carton may be unwound directly from the carton with a minimum of attention on the part of the operator or attendant.

FIG. 3 diagrammatically illustrates a carton 10 of roving packages 32 being fed into a fiber chopping machine 51 (illustrated schematically) from whence the fibers fall upon a conveyor 52 to form a mat 54. It will be understood that the fiber chopping machine 51 is merely illustrative of only one type of machine that may utilize the packed cartons of the instant invention. It will be further understood that a plurality of packed cartons'rnay be employed in Conjunction with one machine and that while only a single roving strand may be seen in FIG. 3, it is the usual practice to feed a plurality of roving strands into a single chopping machine. 7

In the drawings, the strand packages are shown to be positioned with their longitudinal axes extending in a vertical direction and with the strand being unwound from the interiors of the individual packages; however, it is to be understood that the packages may be positioned with their longitudinal axes in any suitable direction and that the strand may be unwound from the exteriors of the individual packages, if the packages were previously wound to facilitate such exterior unwinding.

The strands are preferably directed over a guide re 56 which is sufficiently elevated to cause the strands to be Withdrawn generally upwardly so that the individual strand, as it is being unwound from a particular package in a layer, such as layer 36 Where the strand is being ad vanced from a rearward position to a forward position in the row, will not interfere or be interfered by an adjacent package. As the strand in the first package of a row is exhausted, the running strand is automatically transferred to the second package of the horizontal row and such transfer is continued to subsequent packages till the last package in the row is exhausted. It will be understood that the first package in a row may be that in the forward position or that in the rearward position. Upon exhaustion of thelast package, the running strand is then automatically transferredto the package immediately subjacent thereto in the subjacent row. While all of the packages 32 in a layer may not be exhausted simultaneously, the time differential is not equal to that time required to unwind a complete package. During the time when all of the strands in each ofthe columns are being unwound from the first package in the layer after transfer from the preceding layer, the attendant removes the platform which supported the previous and exhausted layer and the grid 49 from the layer being unwound. Before the exhaustion of the last package in a carton, a new carton is placed adjacent to the .first carton and the ends of the last packages of each column of the first carton may be spliced with the respective ends of the first packages 'of the columns in the new carton. Thus meth- 0d and meansare provided for continuously delivering.

a running strand to a continuous operation with the minimum of attention on the part of the attendant.

The advantages of the invention of presecuring or preconnecting all of the packages in a horizontal row and of interconnecting all of the rows in a column together, together with a carton construction which facilitates the transfer of the running strand from package to package and which adapts the cartons for use with a machine requiring continuous delivery will be apparent to those skilled in the art from the foregoing description of the preferred embodiment of the invention. It should be understood that although the packed carton has been described in detail as to its component parts, such detail is for the purpose of illustration and not by way of limitation. The appended claims are therefore intended to cover any modifications coming within the true scope of 4 v packages arranged in horizontal rows and in superposed layers, a platform supporting each superposed layer, inserts separating each of 'the strand packages from an adjacent package in the layer and defining together with said platform a plurality of compartments, each of said packages being interconnected with the other packages in the respective row, each row of a superposed layer being interconnected with the corresponding row of a subjacent layer, and at least one of the end compartments of a row having an opening in the corresponding platform portion through which opening the strand of a'superposed layer extends to a subjacent layer.

3. A packed carton as described in claim 2 wherein each of the end compartments of a row have openings in the corresponding platform section.

4. A supply of wound yarn packages comprising a plurality of strand packages arranged in horizontal rows and in superposed layers, a platform supporting each superposed layer, each of said packages being interconnected with the other packages in the respective row, each row of a superposed layer being interconnected with the corresponding row of a subjacent layer, and said platform havingan opening at least at one end of each row through which opening the strand of a superposed layer extends to a subjacent layer.

5 The method of unwinding a plurality of yarn packages arranged in a horizontal row and in superposed layers interconnected to provide a unitary continuous running strand, there being a platform supporting each superposed layer, which comprises: initiating withdrawal of the roving strand from the interior of the first package of a horizontal row in an upward direction in its path to the withdrawing force, unwinding said strand from said package until it is exhausted, automatically transferring the running. motion of the strand to the interior of the second package in the row, continuing the unwinding step in respect to the second package, repeating the transferring and unwinding steps in respectto the remaining packages inthe row, upon exhaustion of the last package in the row automatically transferring the running motion of the strand to a package of the subjacent row and removing the platform which supported the exhausted layer, and repeating the unwinding and transferring steps in respect to the strand packages of the, remaining subjacent rows.

' 6. The method of unwinding a plurality of yarn pack ages arranged in a horizontal row and in superposed layers interconnected to provide a unitary'continuous running strand and feeding to a continuous process machine, there being a platform supporting each superposed, layer, which comprises: initiating withdrawal of the yarn strand from the interior of the first yarn package of a horizontal row, initially advancing said strandrfrorn'said package in an upward direction in its path tothe withdrawing force, unwinding said strand from said first package until it is exhausted, automatically transferring the running motion of the strand to the interior of the second package in the row, continuing the unwinding step in respect to the second package whilecontinuing the advancement of strand in an upward direction, repeating the transferring and unwinding steps in respect to the remaining packages in the row, upon exhaustion of the last package in the row I automatically transferring a running motion of the strand to a package of the subjacent row and removing the platformwhich supported the exhausted layer, and repeating the unwinding and transferring steps in respect to the strand packages of the subjacent rows;

7. The method of unwinding a plurality of yarn packages arranged'in horizontal rows and in superposed layers of the carton through which opening the strand of a interconnected to provide a unitary continuous running strand, there being a platform supporting each superposed layer which comprises: initiating withdrawal of the continuous strand from a first package of a horizontal row, unwinding saidstrand from said package until it is exhausted, automatically transferring the running motion of the strand to a second package in the row, continuing the unwinding steps in respect to the second package, repeating the transferring and unwinding steps in respect to the remaining packages in the row, upon exhaustion of the last package in the row automatically transferring the running motion of the strand to a package of a subjacent row, removing the platform which supported the exhausted layer, and repeating the unwinding and transferring steps in respect to the strand packages of the remaining subjacent rows.

8. The method as described in claim 7 wherein a plurality of strands are being simultaneously unwound from packages corresponding to the same number of columnar rows and positioned on a common platform.

9. The method of forming a packed carton of strand packages, which comprises:

(a) arranging a first horizontal layer of strand packages in rows, each row comprising a plurality of strand packages; 5

(b) tying the trailing end of each prior package in a row with the forward end of an adjacent and subsequent package in the row,

(0) placing a platform, having apertures at the terminal ends thereof corresponding to the rows of strand packages in said first layer, on top of said first layer,

(0!) arranging a second and superjacent horizontal layer of strand packages in rows, the number of rows of plural strand packages corresponding in number to that of said first and subjacent layer;

(e) repeating step (b) in regard to the packages of said superjacent layer,

( tying the trailing ends of the end packages of said superjacent layer at one end of the platform with the forward ends of the corresponding packages of the subjacent layer to provide a continuous strand passing through the corresponding aperture of the plat layers;

(g) repeating the above steps in respect to any further superjacent layers, Withthe packages at one end of the rows of any intermediate layer being interconnected with asuperjacent row and with the end packages at the end opposite to said one end of the rows of any intermediate layer being interconnected with a subjacent layer.

10. The method of forming a continuous supply of yarn packages comprising: arranging a plurality of strand packages in horizontal rows to form a first layer, all of the packages within a row being interconnected with the adjacent packages within the row, placing a platform over the first formed layer, forming a second layer of packages on said platform in the manner that said first layer was formed with one of the end packages of each row in said second layer being interconnected with the corresponding endpackage of said first layer, placing a platform over the second formed layer and forming a third layer of packages on the platform resting on said second formed layer in the manner of said first layer, with the end package of each row in said third layer; at the end of the row opposite to that at which said first and second layers are interconnected, being interconnected with the corresponding end packages of said second layer. v

Fleming Jan. 11, 1921 Burnett July 10, 196 2 

1. A PACKED CARTON COMPRISING A PLURALITY OF STRAND PACKAGES ARRANGED IN HORIZONTAL ROWS AND IN SUPERPOSED LAYERS, A PLATFORM SUPPORTING EACH SUPERPOSED LAYER, EACH OF SAID PACKAGES BEING INTERCONNECTED WITH THE OTHER PACKAGES IN THE RESPECTIVE ROW, EACH ROW OF A SUPERPOSED LAYER BEING INTERCONNECTED WITH THE CORRESPONDING ROW OF A SUBJACENT LAYER, AND THERE BEING AN OPENING AT LEAST ONE END OF EACH ROW BETWEEN THE PLATFORM AND THE SIDE WALL OF THE CARTON THROUGH WHICH OPENING THE STRAND OF A SUPERPOSED LAYER EXTENDS TO A SUBJACENT LAYER. 